EP2843129A1 - Reinforced gypsum board having improved fire resistance - Google Patents

Reinforced gypsum board having improved fire resistance Download PDF

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Publication number
EP2843129A1
EP2843129A1 EP13290205.7A EP13290205A EP2843129A1 EP 2843129 A1 EP2843129 A1 EP 2843129A1 EP 13290205 A EP13290205 A EP 13290205A EP 2843129 A1 EP2843129 A1 EP 2843129A1
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EP
European Patent Office
Prior art keywords
fibrous mat
fibres
polymeric binder
mat
gypsum board
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP13290205.7A
Other languages
German (de)
French (fr)
Other versions
EP2843129B2 (en
EP2843129B8 (en
EP2843129B1 (en
Inventor
Sophie Lelogeay
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Saint Gobain Placo SAS
Original Assignee
Saint Gobain Placo SAS
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Application filed by Saint Gobain Placo SAS filed Critical Saint Gobain Placo SAS
Priority to EP13290205.7A priority Critical patent/EP2843129B2/en
Priority to PL13290205.7T priority patent/PL2843129T5/en
Priority to HK16105146.4A priority patent/HK1217114B/en
Priority to RU2016111738A priority patent/RU2644458C2/en
Priority to TW103130021A priority patent/TWI606920B/en
Priority to AU2014314116A priority patent/AU2014314116B2/en
Priority to KR1020167006794A priority patent/KR20160048829A/en
Priority to JP2016537312A priority patent/JP2016531778A/en
Priority to SG11201601326WA priority patent/SG11201601326WA/en
Priority to MYPI2016700620A priority patent/MY176229A/en
Priority to US14/914,905 priority patent/US20160208439A1/en
Priority to PCT/EP2014/068416 priority patent/WO2015028631A1/en
Priority to CN201480047811.5A priority patent/CN105492690B/en
Priority to CA2921933A priority patent/CA2921933C/en
Publication of EP2843129A1 publication Critical patent/EP2843129A1/en
Priority to ZA2016/01262A priority patent/ZA201601262B/en
Publication of EP2843129B1 publication Critical patent/EP2843129B1/en
Application granted granted Critical
Publication of EP2843129B8 publication Critical patent/EP2843129B8/en
Publication of EP2843129B2 publication Critical patent/EP2843129B2/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H21/00—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties
    • D21H21/14—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties characterised by function or properties in or on the paper
    • D21H21/22—Agents rendering paper porous, absorbent or bulky
    • D21H21/24—Surfactants
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B32B13/02—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material with fibres or particles being present as additives in the layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/02—Layered products essentially comprising sheet glass, or glass, slag, or like fibres in the form of fibres or filaments
    • B32B17/04—Layered products essentially comprising sheet glass, or glass, slag, or like fibres in the form of fibres or filaments bonded with or embedded in a plastic substance
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D1/00—Woven fabrics designed to make specified articles
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/20—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
    • D03D15/242—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads inorganic, e.g. basalt
    • D03D15/267—Glass
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/92—Protection against other undesired influences or dangers
    • E04B1/94—Protection against other undesired influences or dangers against fire
    • E04B1/941—Building elements specially adapted therefor
    • E04B1/942—Building elements specially adapted therefor slab-shaped
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/02—2 layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/22—Fibres of short length
    • B32B2305/28—Fibres of short length in the form of a mat
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2401/00—Physical properties
    • D10B2401/02—Moisture-responsive characteristics
    • D10B2401/022—Moisture-responsive characteristics hydrophylic
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2505/00—Industrial
    • D10B2505/08—Upholstery, mattresses
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H13/00—Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
    • D21H13/36—Inorganic fibres or flakes
    • D21H13/38—Inorganic fibres or flakes siliceous
    • D21H13/40—Inorganic fibres or flakes siliceous vitreous, e.g. mineral wool, glass fibres
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/043—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres of plaster

Definitions

  • the present invention relates to gypsum boards comprising fibrous mat facers, as well as fibrous mats for use as such facers.
  • the formaldehyde-free binders in use generally comprise flame-retardants, in order to increase fire resistance.
  • the present invention provides a mat for use as a gypsum reinforcement, the mat comprising fibres that are bound by a formaldehyde-free binder, wherein acceptable fire resistance is achieved without the need for the incorporation of flame retardants into the binder, and acceptable flexural strength is also achieved.
  • formaldehyde-free means a binder that releases or emits formaldehyde at a level of below 10 ⁇ g/m 3 , preferably below 5 ⁇ g/m 3 after 28 days, according to the ISO 16000 standard test.
  • the present invention may provide a gypsum board having two opposed faces, wherein a fibrous mat is embedded in one of the faces of the board, the fibrous mat comprising fibres that are bound by a polymeric binder, wherein the polymeric binder is substantially formaldehyde-free, the length of the fibres is greater than 20 mm, and the diameter of the fibres is greater than 14 micron.
  • the fibrous mat provides a facer for the board.
  • the polymeric binder is hydrophilic.
  • the binder may be intrinsically hydrophilic, or may be provided with hydrophilic properties through the presence of a hydrophilic additive.
  • the mat may be wholly embedded in the face of the board. That is, gypsum layers are present on both the inner and outer surfaces of the mat. Typically, these embodiments are formed when gypsum slurry that has been deposited on an inner surface of the mat is caused to penetrate through the mat, thus providing an outer layer of gypsum that masks the outer surface of the mat. As is well-known in the art, the penetration of gypsum slurry through the mat may be aided by the action of rollers (as described in e.g. US 6,524,679 ) or the application of vibration (as described in e.g. US 4,378,405 ).
  • the mat may be only partially embedded in the face of the board, that is, there is no complete outer layer of gypsum that masks the mat.
  • the length of the fibres in the mat is greater than 22 mm, more preferably greater than 23 mm. It is thought that by increasing the fibre length, the mat is able to continue to provide reinforcement to the gypsum board in the event of a fire even after the binder has largely been burned off. Thus, board integrity is maintained and the progress of the fire is inhibited, even in the absence of flame retardants.
  • the fibre length is less than 30 mm, preferably less than 28 mm, more preferably less than 27 mm.
  • the hydrophilic nature of the polymeric binder ensures good penetration of the fibrous mat by gypsum slurry during the production process, such that acceptable levels of flexural strength are achieved.
  • the diameter of the fibres is greater than 15 micron. In general, the diameter of the fibres is less than 30 micron, preferably less than 20 micron.
  • the polymeric binder for the mat may comprise an acrylate polymer, such as polycarboxylate; poly(meth)acrylate; an acrylate-methacrylate copolymer; a styrene acrylic copolymer; a styrene methacrylic copolymer; a styrene butadiene copolymer; or a mixture thereof.
  • the polymeric binder comprises a hydrophilic additive.
  • Suitable hydrophilic additives include polysorbate surfactants (such as polyoxyethylene sorbitan monolaurate) and non-ionic surfactant copolymers of polyoxyethylene and polyoxypropylene.
  • Suitable acrylate polymers are Acronal DS 2416 (from BASF); Acrodur DS 3530 (from BASF); Aquaset TF 150 (from Dow); HF05 (from Dow); and Acronal DS 5350 (from BASF).
  • Acronal DS 2416 may be preferred as the polymeric binder, as it does not require the addition of a separate hydrophilic species.
  • the polymeric binder is a thermoplastic polymer or an elastomer.
  • the fibrous mat comprises glass fibres, such as E-glass.
  • the fibrous mat may comprise other inorganic fibres, such as rock wool (e.g. produced from basalt).
  • the mat typically comprises mineral fibres in an amount of 10-1100 g/m 2 , preferably 20-300 g/m 2 .
  • the binder is generally present in an amount of 5-350% relative to the weight of the mat of mineral fibres, preferably from 10 to 100%, and advantageously from 15 to 30%.
  • the present invention may provide a fibrous mat comprising fibres that are bound by a hydrophilic polymeric binder, wherein the polymeric binder is substantially formaldehyde-free, the length of the fibres is greater than 20 mm, and the diameter of the fibres is greater than 14 micron, the mat being for embedding in gypsum to provide a gypsum board according to the first aspect of the invention.
  • the fibrous mat according to the second aspect of the invention may comprise one or more optional features of the mat that is embedded in one of the faces of the gypsum board according to the first aspect of the invention.
  • the binder may be applied to the mat through a spray-coating process, or through the use of rollers.
  • the binder may be applied to the mat by means of an applicator that delivers a controlled supply of binder material onto the mat, as the mat is conveyed past the applicator opening.
  • the binder material may be deposited onto the mat and a distributed across the mat by means of a scraper element.
  • the suspension of glass yarns obtained is transferred to a device which makes it possible to produce a mat.
  • the device comprises a container having a perforated base that allows for fluid communication between the internal volume of the container and a suction apparatus located beneath the container.
  • the suspension is deposited in the container and homogenised by vigorous stirring, and then the suction apparatus is activated so as to remove the fluid.
  • a mat of glass fibres with dimensions of 30cm x 30cm and having a weight per surface area of 28.2 g/cm 2 is recovered on the screen.
  • the mat is immersed for 1 minute in an aqueous solution of acrylic resin (Acronal DS 2416, sold by BASF).
  • Acrylic resin Adcronal DS 2416, sold by BASF.
  • the excess binder in the mat is removed by suction and then the mat is heated at 210°C for 1 minute in order to consolidate it. After this treatment, the mat contains 5 g/m 2 of acrylic resin.
  • Example 2 and Comparative Examples 3-6 relate to gypsum boards having embedded glass fibre mats on both faces.
  • the characteristics of the glass fibre mats are summarised in Table 1.
  • Gypsum boards according to Example 2 and Comparative Examples 3-6 were subjected to a fire resistance test in accordance with BS:EN 1364 1:1999. Briefly stated, a partition was constructed in which a frame was clad on each face with a single layer of 12.5 mm thick boards. One side of the partition was exposed to a furnace fire.
  • Example 2 Additional fire testing of gypsum boards according to Example 2 and Comparative Examples 3-6 was carried out using the methodology of BS EN 1363-1:1999. Briefly stated, a steel beam was clad with a single layer of 20 mm think boards and exposed to a furnace fire.
  • the performance of the boards was characterised as satisfactory if the mean temperature of the steel beam remained below 550°C for at least 82 minutes, and the boards retained their mechanical integrity for over 90 minutes.
  • Gypsum boards according to Example 2 and Comparative Examples 3-6 were subjected to a test of flexural strength according to the method set out in BS:EN 520. The performance of the boards was characterised as satisfactory if the flexural strength exceeded a predetermined level. The results are given in Table 1.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Inorganic Chemistry (AREA)
  • Civil Engineering (AREA)
  • Textile Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Building Environments (AREA)
  • Laminated Bodies (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
  • Nonwoven Fabrics (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Dry Formation Of Fiberboard And The Like (AREA)

Abstract

A gypsum board has two opposed faces, and a fibrous mat being embedded in one of the faces of the board. The fibrous mat comprises fibres that are bound by a polymeric binder. The length of the fibres is greater than 20 mm, and the diameter is greater than 14 micron. The polymeric binder is substantially formaldehyde-free. The fibrous mat achieves fire resistance in the gypsum board without the need to incorporate flame retardants into the binder, as well as providing flexural strength.

Description

    Field of the invention
  • The present invention relates to gypsum boards comprising fibrous mat facers, as well as fibrous mats for use as such facers.
    • Background to the invention
  • It is known to create gypsum boards for use e.g. in construction, by depositing a layer of gypsum slurry between two opposing paper liners. However, in an effort to maintain board performance even in humid environments, it has been proposed to replace the paper facing sheets with opposing layers formed, in part, from glass fibre mats. The fibres of such mats are typically bound using a urea formaldehyde resin binder.
  • Due to concerns about the odour of volatile organic compounds emitted from urea formaldehyde resins, as well as the need to comply with regulations limiting the levels of these compounds, it is desirable to provide substantially formaldehyde-free binders for mats.
  • The formaldehyde-free binders in use generally comprise flame-retardants, in order to increase fire resistance.
    • Summary of the invention
  • At its most general, the present invention provides a mat for use as a gypsum reinforcement, the mat comprising fibres that are bound by a formaldehyde-free binder, wherein acceptable fire resistance is achieved without the need for the incorporation of flame retardants into the binder, and acceptable flexural strength is also achieved.
  • As used herein, the term "formaldehyde-free" means a binder that releases or emits formaldehyde at a level of below 10 µg/m3, preferably below 5 µg/m3 after 28 days, according to the ISO 16000 standard test.
  • In a first aspect, the present invention may provide a gypsum board having two opposed faces, wherein a fibrous mat is embedded in one of the faces of the board, the fibrous mat comprising fibres that are bound by a polymeric binder, wherein the polymeric binder is substantially formaldehyde-free, the length of the fibres is greater than 20 mm, and the diameter of the fibres is greater than 14 micron.
  • Effectively, the fibrous mat provides a facer for the board.
  • Preferably, the polymeric binder is hydrophilic. The binder may be intrinsically hydrophilic, or may be provided with hydrophilic properties through the presence of a hydrophilic additive.
  • In certain embodiments, the mat may be wholly embedded in the face of the board. That is, gypsum layers are present on both the inner and outer surfaces of the mat. Typically, these embodiments are formed when gypsum slurry that has been deposited on an inner surface of the mat is caused to penetrate through the mat, thus providing an outer layer of gypsum that masks the outer surface of the mat. As is well-known in the art, the penetration of gypsum slurry through the mat may be aided by the action of rollers (as described in e.g. US 6,524,679 ) or the application of vibration (as described in e.g. US 4,378,405 ).
  • In other embodiments, the mat may be only partially embedded in the face of the board, that is, there is no complete outer layer of gypsum that masks the mat.
  • Preferably, the length of the fibres in the mat is greater than 22 mm, more preferably greater than 23 mm. It is thought that by increasing the fibre length, the mat is able to continue to provide reinforcement to the gypsum board in the event of a fire even after the binder has largely been burned off. Thus, board integrity is maintained and the progress of the fire is inhibited, even in the absence of flame retardants.
  • In general, the fibre length is less than 30 mm, preferably less than 28 mm, more preferably less than 27 mm.
  • The hydrophilic nature of the polymeric binder ensures good penetration of the fibrous mat by gypsum slurry during the production process, such that acceptable levels of flexural strength are achieved.
  • Preferably, the diameter of the fibres is greater than 15 micron. In general, the diameter of the fibres is less than 30 micron, preferably less than 20 micron.
  • The polymeric binder for the mat may comprise an acrylate polymer, such as polycarboxylate; poly(meth)acrylate; an acrylate-methacrylate copolymer; a styrene acrylic copolymer; a styrene methacrylic copolymer; a styrene butadiene copolymer; or a mixture thereof. Optionally the polymeric binder comprises a hydrophilic additive. Suitable hydrophilic additives include polysorbate surfactants (such as polyoxyethylene sorbitan monolaurate) and non-ionic surfactant copolymers of polyoxyethylene and polyoxypropylene. Suitable acrylate polymers are Acronal DS 2416 (from BASF); Acrodur DS 3530 (from BASF); Aquaset TF 150 (from Dow); HF05 (from Dow); and Acronal DS 5350 (from BASF).
  • Acronal DS 2416 may be preferred as the polymeric binder, as it does not require the addition of a separate hydrophilic species.
  • Typically, the polymeric binder is a thermoplastic polymer or an elastomer.
  • In general, the fibrous mat comprises glass fibres, such as E-glass. Alternatively, the fibrous mat may comprise other inorganic fibres, such as rock wool (e.g. produced from basalt).
  • The mat typically comprises mineral fibres in an amount of 10-1100 g/m2, preferably 20-300 g/m2. The binder is generally present in an amount of 5-350% relative to the weight of the mat of mineral fibres, preferably from 10 to 100%, and advantageously from 15 to 30%.
  • In a second aspect, the present invention may provide a fibrous mat comprising fibres that are bound by a hydrophilic polymeric binder, wherein the polymeric binder is substantially formaldehyde-free, the length of the fibres is greater than 20 mm, and the diameter of the fibres is greater than 14 micron, the mat being for embedding in gypsum to provide a gypsum board according to the first aspect of the invention.
  • The fibrous mat according to the second aspect of the invention may comprise one or more optional features of the mat that is embedded in one of the faces of the gypsum board according to the first aspect of the invention.
  • Several methods are known in the art for applying the binder to the mat. For example, the binder may be applied to the mat through a spray-coating process, or through the use of rollers. In other processes, the binder may be applied to the mat by means of an applicator that delivers a controlled supply of binder material onto the mat, as the mat is conveyed past the applicator opening. In an alternative process, the binder material may be deposited onto the mat and a distributed across the mat by means of a scraper element.
    • Detailed description
  • The invention will now be described by way of example only.
    • Example 1
  • Two litres of an aqueous solution comprising 250 g of hydroxyethycellulose (thickener: sold under the reference Natrosol™ by Hercules) and 0.3 g of an ethoxylated octadecyclamine/octadecylguanidine complex (surface agent: sold under the reference Aerosol C-61 by Cytec; solids content: 70%) were prepared.
  • 2.54 g of cut yarns (length: 24 mm; diameter: 16 micron) of E-glass were added to the solution.
  • The suspension of glass yarns obtained is transferred to a device which makes it possible to produce a mat. The device comprises a container having a perforated base that allows for fluid communication between the internal volume of the container and a suction apparatus located beneath the container.
  • The suspension is deposited in the container and homogenised by vigorous stirring, and then the suction apparatus is activated so as to remove the fluid. A mat of glass fibres with dimensions of 30cm x 30cm and having a weight per surface area of 28.2 g/cm2 is recovered on the screen.
  • The mat is immersed for 1 minute in an aqueous solution of acrylic resin (Acronal DS 2416, sold by BASF). The excess binder in the mat is removed by suction and then the mat is heated at 210°C for 1 minute in order to consolidate it. After this treatment, the mat contains 5 g/m2 of acrylic resin.
    • Example 2 and Comparative Examples 3-6
  • Example 2 and Comparative Examples 3-6 relate to gypsum boards having embedded glass fibre mats on both faces. The characteristics of the glass fibre mats are summarised in Table 1.
    • Fire resistance: test 1
  • Gypsum boards according to Example 2 and Comparative Examples 3-6 were subjected to a fire resistance test in accordance with BS:EN 1364 1:1999. Briefly stated, a partition was constructed in which a frame was clad on each face with a single layer of 12.5 mm thick boards. One side of the partition was exposed to a furnace fire.
  • The performance of the boards was characterised as satisfactory if the average temperature on the unexposed face of the partition remained below 140°C for at least 60 minutes. The results are summarised in Table 1.
    • Fire resistance: test 2
  • Additional fire testing of gypsum boards according to Example 2 and Comparative Examples 3-6 was carried out using the methodology of BS EN 1363-1:1999. Briefly stated, a steel beam was clad with a single layer of 20 mm think boards and exposed to a furnace fire.
  • The performance of the boards was characterised as satisfactory if the mean temperature of the steel beam remained below 550°C for at least 82 minutes, and the boards retained their mechanical integrity for over 90 minutes.
    • Testing flexural strength
  • Gypsum boards according to Example 2 and Comparative Examples 3-6 were subjected to a test of flexural strength according to the method set out in BS:EN 520. The performance of the boards was characterised as satisfactory if the flexural strength exceeded a predetermined level. The results are given in Table 1.
    • Characterisation of slurry penetration
  • The extent of slurry penetration through the fibrous mat was characterised through visual inspection and was classified as "satisfactory" if the penetration was complete and the resulting board surface was flat. The results are given in Table 1. Table 1
    Example Binder Fibre diameter (micron) Fibre length (mm) Grammage (mass per unit area of fibres + binder in g/m2) Slurry penetration Flexural strength Fire resistance: Fire resistance:
    test 1 test 2
    Comparative Example 3 Urea Formaldehyde 16 24 70 Satisfactory Satisfactory Satisfactory Satisfactory
    Comparative Example 4 Polycarboxylate 13 18 75 Unsatisfactory Unsatisfactory Not tested Not tested
    Comparative Example 5 Polycarboxylate 13 18 70 Unsatisfactory Satisfactory Satisfactory Unsatisfactory
    Comparative Example 6 Polycarboxylate 16 24 70 Unsatisfactory Not tested Not tested Not tested
    Example 2 Acrylic (wettable) 16 24 70 Satisfactory Satisfactory Satisfactory Satisfactory

Claims (15)

  1. A gypsum board having two opposed faces, wherein a fibrous mat is embedded in one of the faces of the board, the fibrous mat comprising fibres that are bound by a polymeric binder, wherein the polymeric binder is substantially formaldehyde-free, the length of the fibres is greater than 20 mm, and the diameter of the fibres is greater than 14 micron.
  2. A gypsum board according to claim 1, wherein the polymeric binder is hydrophilic.
  3. A gypsum board according to claim 1 or claim 2, wherein the fibrous mat is wholly embedded in the face of the board.
  4. A gypsum board according to claim 1 or claim 2, wherein the fibrous mat is partially embedded in the face of the board.
  5. A fibrous mat comprising fibres that are bound by a polymeric binder, wherein the polymeric binder is substantially formaldehyde-free, the length of the fibres is greater than 20 mm, and the diameter of the fibres is greater than 14 micron, the mat being for embedding in gypsum to provide a gypsum board according to any one of claims 1 to 4.
  6. A fibrous mat according to claim 5, wherein the polymeric binder is hydrophilic.
  7. A fibrous mat according to claim 5 or claim 6, wherein the polymeric binder is selected from the group consisting of: acrylate polymers; methacrylate polymers; acrylate-methacrylate copolymers; styrene acrylic copolymers; styrene-methacrylate copolymers; styrene butadiene copolymers; and mixtures thereof.
  8. A fibrous mat according to claim 7, wherein the polymeric binder further comprises a hydrophilic additive.
  9. A fibrous mat according to claim 8, wherein the hydrophilic additive is selected from the group consisting of: polysorbate surfactants (such as polyoxyethylene sorbitan monolaurate) and non-ionic surfactants copolymers of polyoxyethylene and polyoxypropylene.
  10. A fibrous mat according to claim 8 or claim 9, wherein the acrylate polymer is selected from the group comprising: Acrodur DS 3530 (from BASF); Aquaset TF 150 (from Dow); and HF05 from Dow.
  11. A fibrous mat according to claim 7, wherein the acrylate polymer is Acronal DS 2416 (from BASF).
  12. A fibrous mat according to any one of claims 5 to 11, wherein the fibrous mat comprises glass fibres.
  13. A fibrous mat according to any one of claims 5-12, wherein the diameter of the fibres is greater than 15 micron, preferably greater than 16 micron.
  14. A fibrous mat according to any one of claims 5-13, wherein the length of the fibres is greater than 22 mm, preferably greater than 23 mm.
  15. A fibrous mat according to any one of claims 5-14, wherein the mat is a non-woven mat.
EP13290205.7A 2013-08-30 2013-08-30 Reinforced gypsum board having improved fire resistance Active EP2843129B2 (en)

Priority Applications (15)

Application Number Priority Date Filing Date Title
EP13290205.7A EP2843129B2 (en) 2013-08-30 2013-08-30 Reinforced gypsum board having improved fire resistance
PL13290205.7T PL2843129T5 (en) 2013-08-30 2013-08-30 Reinforced gypsum board having improved fire resistance
US14/914,905 US20160208439A1 (en) 2013-08-30 2014-08-29 Reinforced Gypsum Board Having Improved Fire Resistance
PCT/EP2014/068416 WO2015028631A1 (en) 2013-08-30 2014-08-29 Reinforced gypsum board having improved fire resistance
TW103130021A TWI606920B (en) 2013-08-30 2014-08-29 Reinforced gypsum board having improved fire resistance
AU2014314116A AU2014314116B2 (en) 2013-08-30 2014-08-29 Reinforced gypsum board having improved fire resistance
KR1020167006794A KR20160048829A (en) 2013-08-30 2014-08-29 Reinforced gypsum board having improved fire resistance
JP2016537312A JP2016531778A (en) 2013-08-30 2014-08-29 Reinforced gypsum board with improved fire resistance
SG11201601326WA SG11201601326WA (en) 2013-08-30 2014-08-29 Reinforced gypsum board having improved fire resistance
MYPI2016700620A MY176229A (en) 2013-08-30 2014-08-29 Reinforced gypsum board having improved fire resistance
HK16105146.4A HK1217114B (en) 2013-08-30 2014-08-29 Reinforced gypsum board having improved fire resistance
RU2016111738A RU2644458C2 (en) 2013-08-30 2014-08-29 Reinforced gypsum plasterboard sheet with improved fire resistance
CN201480047811.5A CN105492690B (en) 2013-08-30 2014-08-29 Reinforced plasterboard with improved fire resistance
CA2921933A CA2921933C (en) 2013-08-30 2014-08-29 Reinforced gypsum board having improved fire resistance
ZA2016/01262A ZA201601262B (en) 2013-08-30 2016-02-24 Reinforced gypsum board having improved fire resistance

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP13290205.7A EP2843129B2 (en) 2013-08-30 2013-08-30 Reinforced gypsum board having improved fire resistance

Publications (4)

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EP2843129A1 true EP2843129A1 (en) 2015-03-04
EP2843129B1 EP2843129B1 (en) 2020-05-13
EP2843129B8 EP2843129B8 (en) 2020-06-17
EP2843129B2 EP2843129B2 (en) 2023-06-07

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EP (1) EP2843129B2 (en)
JP (1) JP2016531778A (en)
KR (1) KR20160048829A (en)
CN (1) CN105492690B (en)
AU (1) AU2014314116B2 (en)
CA (1) CA2921933C (en)
MY (1) MY176229A (en)
PL (1) PL2843129T5 (en)
RU (1) RU2644458C2 (en)
SG (1) SG11201601326WA (en)
TW (1) TWI606920B (en)
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ZA (1) ZA201601262B (en)

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Also Published As

Publication number Publication date
WO2015028631A1 (en) 2015-03-05
US20160208439A1 (en) 2016-07-21
EP2843129B2 (en) 2023-06-07
EP2843129B8 (en) 2020-06-17
RU2644458C2 (en) 2018-02-12
EP2843129B1 (en) 2020-05-13
CA2921933A1 (en) 2015-03-05
TWI606920B (en) 2017-12-01
TW201514000A (en) 2015-04-16
CN105492690B (en) 2018-09-18
RU2016111738A (en) 2017-10-04
PL2843129T5 (en) 2023-09-18
HK1217114A1 (en) 2016-12-23
MY176229A (en) 2020-07-24
JP2016531778A (en) 2016-10-13
AU2014314116A1 (en) 2016-03-10
CA2921933C (en) 2021-05-18
SG11201601326WA (en) 2016-03-30
ZA201601262B (en) 2017-11-29
AU2014314116B2 (en) 2017-09-14
PL2843129T3 (en) 2020-10-19
KR20160048829A (en) 2016-05-04
CN105492690A (en) 2016-04-13

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